Manitou SIX Elite, SIX Super suspension fork Owner's manual

• ENGLISH
MANITOU SUSPENSION FORKS
CONGRATULATIONS ON CHOOSING A 2002 MANITOU SIX FORK. This Manitou SIX fork is fully assembled and ready to be installed onto your bicycle. It comes
equipped with a 1 1/8-inch threadless steerer tube and is available with a V-brake-style hangerless arch (or there’s an optional attachable cable hanger which is available
through your dealer). SIX forks are also available in a disc brake only version.
2002 MANITOU SIX FORK LINE
SIX ELITE.....................80 OR 100 MM TRAVEL* / COIL SPRINGS / FLUID FLOW DAMPING / SINGLE CROWN
SIX SUPER ..................80 OR 100 MM TRAVEL* / COIL SPRINGS / FLUID FLOW DAMPING (REBOUND ADJUSTABLE) / SINGLE CROWN
*Preset from the factory, but changeable. See the Convertible Travel section in the Dealer Service Addendum for details.
You can also download this manual at www.answerproducts.com.
BICYCLING IS A HAZARDOUS ACTIVITY THAT REQUIRES THAT THE RIDER STAY IN CONTROL OF HIS OR HER BICYCLE AT ALL
TIMES. READING THIS MANUAL ENTIRELY, AND PROPERLY MAINTAINING YOUR BICYCLE AND SUSPENSION FORK, WILL
REDUCE THE POSSIBILITY OF INJURY OR POSSIBLE DEATH. PRIOR TO RIDING YOUR BICYCLE, YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE THAT NO
DAMAGE HAS OCCURRED DURING THE COURSE OF RIDING. DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING, CRACKING, CREAKING, LEAKING, OR IF IT IS MISSING ANY OF THE ORIGINALLY SUPPLIED COMPONENTS. ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH.
FOLLOWING THESE INSTRUCTIONS CAN HELP YOU REDUCE THE RISK OF BEING INJURED. IF YOU ARE A MODERATE OR AGGRESSIVE OFF-ROAD RIDER, OR RIDE AT
LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN, ANSWER RECOMMENDS RETURNING YOUR SUSPENSION FORK EVERY 2 YEARS FOR A THOROUGH INSPECTION
AND UPDATE. TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO ANSWER PRODUCTS, OR YOU MAY CALL ANSWER AT
(661) 257-4411 TO HAVE YOUR FORK SHIPPED DIRECTLY.
IMPORTANT: The SIX fork is an off-road fork, and as such, does not come with proper reflectors for on-road use. Have your dealer or mechanic install proper
reflectors to meet the Consumer Product Safety Commission’s (C.P.S.C.) Requirements for Bicycles if the fork is going to be used on public roads at any time. If
you have questions regarding C.P.S.C. Standards, or would like to purchase a reflector bracket kit (Part #85-3674), contact your dealer.
CONSUMER SAFETY INFORMATION
WARRANTY INFORMATION
1. Never remove or have the steerer tube or stanchions removed from the crown.
The steerer tube and stanchions (inner legs) are press fit at the factory. Press
fit inner legs have higher performance versus bolt-in inner legs, but can not be
pressed out. Pressing them out will permanently damage the crown beyond
repair and render it unsafe for any continued use.
2. Never attempt to thread a threadless steerer tube. Cutting threads will weaken
the steerer tube and cause an unsafe condition. The only safe thing to do is to
obtain the proper crown/steerer from your dealer, or contact Answer Warranty
Department at (661) 257-4411.
3. Any other alteration or modification to your fork should be considered unsafe.
Contact Answer Warranty Department prior to modifying your fork in any way
for safety information.
4. Do not use the SIX fork if any parts are broken, bent, cracked, or you suspect
may be damaged. Contact your dealer or Answer Warranty Department at
(661) 257-4411 if you have any questions concerning the integrity or condition
of your fork.
5. Answer Products recommends that you inspect your fork before every ride for
wear and damage. Inspect the crown, inner legs, outer legs dropout and brake
arch areas for cracks or damage.
Any Answer Products fork found by the factory to be defective in materials and/or
workmanship within one year from the date of purchase will be repaired or
replaced at the option of the manufacturer, free of charge, when received at the
factory with proof of purchase, freight prepaid. This warranty does not cover
breakage, bending, or damage that may result from crashes or falls. This warranty
does not cover any fork that has been subject to misuse or whose serial number
has been altered, defaced or removed. This warranty does not cover paint damage. Any modifications made by the user will render the warranty null and void.
This warranty is expressly in lieu of all other warranties, and any implied are limited in duration to the same duration as the expressed warranty herein. Answer
Products shall not be liable for any incidental or consequential damages.
If for any reason warranty work is necessary, return the fork to the place of purchase. At that time, instructions for repair, return, or replacement shall be given.
Customers in countries other than USA should contact their dealer or local distributor.
.1.
.2.
Tire Clearance
Reifenabstand
Espacio libre de
la cubierta
Distance arceau/pneu
Spazio libero del pneumatico
Bandspeling
Folga do pneu
Checking Oil Level
Kontrolle des Ölstandes
Verificación del nivel de
aceite
Vérification du niveau
d’huile
Controllo del livello dell’olio
Oliepeil controleren
Verificação do nível de óleo
.3.
.4.
Travel Measurement
Messung der Auslenkung
Cómo medir el recorrido
Mesure de la course
Misurazione della corsa
Meting van loop
Medição do curso
Convertible Travel
Umstellbare
Auslenkung
Cómo cambiar
el recorrido
Changement de
la course
Corsa convertibile
Variabele loop
Curso conversível
INSTALLATION INSTRUCTIONS
Ensure that the proper steerer tube has been delivered on your Manitou SIX. The steerer tube may need to be cut to length to fit your bicycle head tube. If you are not
familiar with this procedure, or do not have the proper tools to cut the steerer tube, it is recommended that you seek a dealer with a qualified bicycle mechanic to perform installation.
THE STEERER TUBE AND STANCHIONS (INNER LEGS) ARE A ONE-TIME PRECISION PRESS FIT AT THE FACTORY AND CANNOT BE REMOVED
FROM THE CROWN. REPLACEMENT OF THE ENTIRE CROWN/STEERER ASSEMBLY MUST BE DONE TO CHANGE STEERER TUBE LENGTHS OR
DIAMETERS. REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE.
BREAK-IN
Your new fork is designed to break in during your first few rides (about 20 hours total riding time). Prior to break-in, you may notice your fork binds slightly and feels
notchy. Following the break-in period, your fork will feel much smoother and will react to bumps much better than when you first put it on your bike. After 20 hours,
you may want to recheck your rebound and preload adjustments (when applicable) to fine tune the fork completely. Between services on your Manitou fork, all you must
do is lubricate your fork as needed with Manitou Prep M (part number 85-3810 for the lube and 85-3812 for the injector gun) via the Microlube grease ports located on
the back of the fork legs.
FORK INSTALLATION
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube. You can use
your old fork as a guide for cutting the steerer tube length.
3. Remove the headset crown race from the old fork and press onto the
Manitou SIX steerer tube until the race is seated over the crown.
4. Clean and grease the headset bearings and races.
5. Install the lower bearings (if applicable) on the fork crown race.
6. Insert the steerer tube into the head tube of the frame.
7. Install the upper bearings, stem spacers, and stem.
8. Install the stem cap and bolt. Tighten the bolt to headset manufacturer’s
specifications.
9. Install the handlebars to desired height and the torque stem pinch screws or
stem clamping system to manufacturer’s specifications.
10. Install the brakes and adjust per the manufacturer’s instructions.
11. For all SIX, adjust the front wheel quick release to clear the 0.275” (7 mm)
thick secondary catch dropout. The quick release must be tightened after it
is properly seated into the dropout counter bores to manufacturer’s specifications. Ensure that there is adequate thread engagement (4 or more threads
with the release adjusted to lock).
NOTE: 2002 Manitou SIX forks are equipped with a secondary catch dropout to
retain the wheel in the fork in the event the quick release comes loose.
WHEN INSTALLING THE WHEEL OR A NEW TIRE, CHECK
TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE
CLEARANCE. MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM
OF THE BRAKE ARCH. THIS MEASUREMENT SHOULD BE 10 MM (FIGURE 1).
IMPORTANT: The Manitou SIX should not be used if any parts appear to be or
are damaged. Contact your local dealer or Answer Products for replacement
parts.
MAINTENANCE
IMPORTANT: Use of fork boots is required to keep your Manitou SIX fork
performing well and the warranty in effect. Use of this fork without boots will
shorten the life of the fork, decrease the time between maintenance intervals,
reduce the performance and void the warranty.
IMPORTANT: When lubricating the fork with lubricant through the lubricant
ports, it is important to note the lubricant is being forced between the upper
and lower bushings. If the area is overfilled, the lubricant may force the upper
bushing and dust seal out. You should only insert lubricant to the level at
which stiction (stickiness when you compress the fork) is no longer felt.
IMPORTANT: Before every ride you should:
1. Ensure that quick release skewers are properly adjusted and tight.
2. Wipe the inner legs and clean and check entire fork for any obvious damage.
3. Check the headset for proper adjustment.
4. Ensure that the front brake cable is properly routed and check brake adjustment.
CHECKING OIL LEVEL
IMPORTANT: Setting the proper oil level in your Fluid Flow damped fork is
critical. Fluid Flow damping is located in the right leg of your Manitou SIX Elite
or Super fork. Not enough oil will allow foaming and reduce the performance.
Too much oil will restrict travel and may cause damage to the system and create an unsafe riding condition. Finish reading this entire section prior to altering the oil level.
To check the oil level on the Manitou SIX, remove the compression assembly
located in the top of the right leg (as you are looking at the fork from the rider’s
position). Leave the left side spring stack in place to keep the fork fully extended.
Use a tape measure or “dip stick” to measure from the top of the fork crown
down to where the oil sits (see figure #2). The oil level for the Manitou SIX should
be per following table.
Fork Model
Manitou SIX Elite/Super
Oil Level
124 - 137 mm (4.9 - 5.4 inches)
NOTE: Use Maxima SAE 5WT fork oil suspension fluid only.
If you have any questions regarding your 2002 Manitou SIX suspension fork, contact the Answer Warranty Department at (661) 257-4411. You can also log on to
www.answerproducts.com and download this manual or see detailed instructions
on how to service your suspension fork.
Thank you again for choosing a 2002 Manitou SIX suspension fork.
DEALER SERVICE ADDENDUM
SIX ELITE AND SUPER
This section is designed to help you tune and maintain your Manitou suspension fork.
MEASURING SAG
To measure sag, you’ll need a tape measure, a pencil,
a piece of paper and a helper.
1. Measure the distance from the front axle’s centerline to the bottom of the
upper crown when no one is sitting on the bike, and write this distance
down. Remember the exact locations of the two points because you’ll need
to use them later.
2. Have the rider sit on the bike and measure the distance between the same
two points as in step one. It is important to be in the normal riding position
(weight centered) with the rider’s feet on the pedals.
3. Subtract the second measurement from the first. The resulting measurement is the static sag or ride height.
SAG MEASUREMENT
Fork Travel
80 mm
100 mm
Sag
12 - 16 mm
18 - 24 mm
TRAVEL MEASUREMENT
To determine which travel your SIX Elite or
Super fork is in, simply measure the distance from the top of the seal area on
the lowers (or the bottom of the fork boot) to the bottom of the crown (see figure #3).
Fork Travel
80 mm
100 mm
Seal-to-Crown Measurement
Around 4.3 inches or 109 mm
Around 5.2 inches or 130 mm
RECOMMENDED SPRINGS
SIX Elite/Super
Standard Set-up
Rider Weight
100- 150 lbs.
150-170 lbs.
170 plus lbs.
Recommended Spring Kit
Soft ride kit (Part #85-4826)
Medium ride kit (Part #85-4827)
Firm ride kit (Part #85-4828)
CHANGING COIL SPRINGS Once you have checked sag, you can either
preload the spring via the cap on top of the left leg, or even better, make
spring changes to accommodate for your riding style and weight.
1. Start by removing the preload adjuster by unscrewing the cap from the top
of the crown/leg assembly. A 1-1/16th inch or 27 mm socket will be necessary with the SIX. Remember: The springs are housed only in the left leg on
2002 Manitou suspension forks.
2. With the adjuster assembly removed, the spring stack is now accessible.
3. Select the appropriate coil spring for your weight and riding style (refer to
the above spring chart for recommended rates).
4. Apply a liberal amount of grease to the outside surface of the new coil
spring. We recommend any thick grease (not light greases like Prep M).
Install the new spring stack.
5. Reinstall the preload adjuster assembly, taking care not to cross-thread the
cap. It should thread in by hand and does not need to be tightened with a
wrench (finger-snug is recommended).
CONVERTIBLE TRAVEL
Changing the travel from 80 to 100 mm or
vice-versa requires the removal of the lower legs. Unthread the 8 mm and
4 mm bolts on the bottom of the fork and pull the lowers free from the uppers.
Then, unscrew the cap on the bottom of the left leg (as seen from the rider’s
position). Remove the clip and insert it into the upper position (above the rod
flange) for 100 mm of travel or the lower position (below the rod flange) for 80
mm of travel (see figure #4).
MICROLUBE All you need is a Microlube lubricant gun (part # 85-3812)
and Manitou’s Prep M (part # 85-3810) suspension fork lubricant. Brush any
dirt from the grease ports, insert the grease gun into the small fitting located
at the back of the fork and squeeze a few times. Continue injecting grease and
push the fork up and down until stiction is eliminated.
MAINTENANCE AND SERVICE
INTRODUCTION When servicing the fork, take the time to inspect all parts
for excessive wear or damage. There are basically four aspects of a fork that
will require attention: the stanchions (inner legs), the bushings in the outer
legs, the spring stack and the damping fluid. Inspecting any of these parts
requires disassembly of the fork. Pay close attention to the bushings, which
can be damaged by contamination in severe conditions. Replace any worn or
damaged parts that are discovered.
SERVICE SCHEDULE Suggested Service for Manitou Forks
Normal Conditions — Short/Infrequent Rides
• Lube fork as needed with Prep M lubricant via the Microlube ports.
• Disassemble, clean and lubricate fork every 4-5 months.
• Lubricate spring stack as needed.
Normal Conditions — Long/Frequent Rides
• Lube fork as needed with Prep M lubricant via the Microlube ports.
• Disassemble, clean and lubricate fork every 10-14 weeks.
• Lubricate spring stack as needed.
Severe Conditions (mud, rain, snow, extreme dust) —
Short/Infrequent Rides
• Lube fork as needed with Prep M lubricant via the Microlube ports.
• Disassemble, clean and lubricate fork every 6-8 weeks.
• Lubricate spring stack as needed.
Severe Conditions (mud, rain, snow, extreme dust) — Long/Frequent Rides
• Lube fork as needed with Prep M lubricant via the Microlube ports
• Disassemble, clean and lubricate fork every 4-6 weeks.
• Lubricate spring stack as needed.
SERVICE PARTS KITS
SIX Elite
SIX Super
A Compression Damping
Assembly
B Rebound Damping
Assembly
C Preload Adjuster
Assembly
D Crown/Steerer Tube
Assembly, Steel
E Outer Casting
Assembly, Black
F Sticker Kit, Black
G Ride Kit Assembly, Soft
Ride Kit Assembly, Med.
Ride Kit Assembly, Firm
I Knob Kit
J Boot Kit
Silver Casting
Black Casting, No Boss
Silver Casting, No Boss
85-4820
85-4821
85-4822
85-4823
85-4825
85-4814
85-4826
85-4827
85-4828
85-4830
85-4824
85-4898
85-4905
85-4906
A Compression Damping
Assembly
B Rebound Damping
Assembly
C Preload Adjuster
Assembly
D Crown/Steerer Tube
Assembly
E Outer Casting Assembly,
Red
F Sticker Kit, Red
G Ride Kit Assembly, Soft
Ride Kit Assembly, Med.
Ride Kit Assembly, Firm
I Knob Kit
J Boot Kit
Red Casting, No Boss
85-4820
85-4831
85-4822
85-4823
85-4834
85-4814
85-4826
85-4827
85-4828
85-4830
85-4824
85-4907
Answer Products Inc.
Customer Service/Warranty Department
28209 Avenue Stanford, Valencia, CA 91355 USA
(661) 257-4411
www.answerproducts.com
SPECIAL OFFERS
Spring kits and Prep M lubricant directly from Answer Products
at a special introductory price for new purchasers
of Manitou forks or Manitou-equipped bikes.
Prep M Grease Gun & Tube: $19.95
Spring Kits: $12.95
International orders add a $15 handling charge, credit card only.
Shipping and handling in the US included in the $19.95 price.
Call Answer Products at 661-257-4411 to order
or visit the website at www.answerproducts.com.
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